Method of making axle blanks



Jan. 17, 1928.

W. P. WITHEROW METHOD OF MAKING AXLE BLANKS 2 Sheets-Sheet 1 Jan. 17, 1928. 1,656,846

w. P. WITHEROW METHOD OF MAKING AXLE BLANKS Filed Dec. 30 1921 2 Sheets-Sheet 2 INVENTOR ww W S Patented Jan. 17, 1928.

UNITED f STATES PATENT OFFICE.

WILLIADI 1P. WITHEROW, OF PITTSBURGH, PENNSYLVANIA, ASSIGNOR, BY MESNE AS- SI'Z'JrNlll'lflNTS, T COLONIAL TRUST COMPANY, TRUSTEE, OF PITTSBURGH, PENNSYL- VANIA, A CORPORATION OF PENNSYLVANIA.

METHOD OF MAKING AXLE BEANKS.

Application filed December 30, 1921. Serial No. 525,979.

Figure l is a perspective view of one form of a rolled leader or blank ready for die rolling;

Figure 2 is a side elevation of a portion of a series of one form of axle blanks as they emerge from the die rolling;

Figure 3 is a top plan view of one of the blanks shown in Figure 2;

Figures 4 and 5 are cross sectional views 1 on the lines IVIV and VV,.respectively, of Figure 2;

Figures 6, 7 and 8 are views similar to Figure 2, showing other forms of die rolled axle blanks embodying my invention;

Figure 9 is a cross-sectional view on the line IX IX of Figure 8;

' Figure IQ is a side elevation of the ends of twoaxleblanks produced in accordance with the present invention, and illustrating the gating connecting the same; and

Figure 11 is a top plan view of the construction illustrated in Figure 10.

My invention relates broadly to the manufacture of vehicle axles, and more particularly the front axles of automotive vehicles.

These axles are generallyof two kinds, one in which the end of the axle itself is split and formed into forks, for receiving a stub axle, 'while in the other, theforked portion is on the stub axle, this forked portion co-operating-with a bored boss at the end of the axle. This latter form is termed the reverse "Elliott type.

Heretofore in making the type of axle :55 having forked ends, the end portions of the original blank have been split and formed into forks, and the main body of the axle has then been forged to shape. Such forged shapes were made slightly shorter between 4 centers than the finished axle, andwere then pulled or stretched to exact length. These operations involved considerable time, expense and labor, as well as the use of heavy and expensive forging hammers and equipment.

My invention relates to the formation of such axles from a rudimentary recessed leader or preliminary blank. This preliminary blank. which may have any one of a large number of shapes, is preferably of uniform cross-section having a cross-sectional shape corresponding in a rudimentary way to the cross-sectional shape of'a portion of the finished die-rolled blank. For example. these front axles as now made usually have a central portion of I-beam cross section, this I- beam either being of the same depth or varying depth between the points of attachment for the springs. In making such axles, my leader is preferably of rudimentary I- beam shape. This leader of uniform crosssection is then rolled in die rolls to form a connected series of axle blanks, which are then cut,sawed or sheared apart. If desired, the ends may be cut to length, or the blanks may be initially rolled from center to center with the ends directly connected or connected by a suitable gating, as illustrated more particularly in Figures 10 and 11. By the expression from center to centeras used herein, I mean from a given point in one blank to a corresponding point in an adjacent blank, to provide a constant distance therebetween or from a given point in one blank to another point in the same blank. The purpose, of course, is to give absolute uniformity in successive blanks, After the individual blanks are separated from the series the flash or finning formed in the die-rolling is trimmed or sheared olf, the blank then being ready for the final operations. These final operations may consist of machining certain portions and in most cases of forging the end portions to the desired final shape.

The dies for giving the desired shape to the rudimentary blank may be set in a roll having a circumference arranged to form one axle blank or a multiple thereof at each revolution. The rolls for this pass are preferably constructed in accordance with the patent of George Baehr, No. 1,289,602 dated December 31st, 1918, and certain other copending applications of the said Baehr.

The dies for making these axle blanks are,

for the central portion, form the spring seats, if required, and make suitably shaped end portions for the blanks,which are thereafter reshaped, as desired.

did

of course, shaped to give the desired section In Figure 1 thereis illustrated one forni' of leader adapted to be rolled in accordance with the present invention, and having a rudimentary I-beam section for producing front axles of the Lbeam type as referred to. In Figures 2, 6, 7 and 8 I show a part of the string of connected blanks of this type coming from the die rolls.

In Figure 2 there are illustrated portions of two blanks each having a central I-beam portion 2 shown as of varying cross-section, the depth of the I-beam increasing toward the thickened 0r boss portions 3 shown in section in Figure4, where the spring attachments are made. Beyond the portions 3, there are short I-beam portions 4 shown in section in Figure 5, which gradually merge into solid end portions 5, preferably of rectangular form in cross-section. Flash or fins 6 are formed on the intermediate portions of the blank during the die-rolling operation, the amount of the flash varying in accordance with the shaping'and reducing operations to which the leader is subjected during the rolling. In die-rolling, a string of these blanks will come from the rolls, the blanks being then sheared apart and trimmed at the ends to the correct length, or directly sheared to exact length when the blanks are rolled from center to center.

Such axle blank, after trimming, may be furnished to the automobile maker who splits and forks the solid end portions to make the fork type of axle, and machines certain parts, such as the portions 3, 3. These blank ends may, however, be forged into bosses instead of yokes in making the reverse Elliott t pe.

In Figure 6 there are illustrated portions of two blanks generally similar to those shown in Figure 2. In this form, however, the central portion 2 of each blank, is of uniform cross-section and each entire blank is rolled to finished dimensions. These blanks have bosses 8 for the attachment of the springs, and short I-beam sections 4, which merge into solid bosses 5 ready to be machined and bored, for axles of the reverse Elliott type, after the blanks are separated and the flash trimmed away. The bosses 3' may be similarly re-shaped or machined.

In Figure 7 the central portion 2 of each blank is shown of I-beam form, this extending into lumps 7', instead of finished bosses. Beyond these lumps theremay be partial finished I-beam portions 4 which mer e into square or rectangular solid end portions 5'. In this case the I-beam portion after trimming off the flash 6 is in finished condition and the lumps form stock from which the spring pads or bosses for spring connection or support are made. The end ortions may be forged into yokes or bosses spending on the type of axle desired.

In Figure 8 I show still another form of blank having the finished I-beam central portion-Q terminating. in lump stock 7 with I-beam portions 4 outside the lump portions and extending to flattened eye portions 5.

illustrated in section in Figure 9. \Vith this form, the webs 8 of the eyes are punched out and the eyes opened to form yokes which are then forged, the lump portions being either reforged; machined or both to provide the spring pads or spring bosses.

In Figures 10 and 11 the adjacent ends 5 of the axle blanks are illustrated as being connected by a gating 10. In many instances it may be desirable to roll the string of blanks with such a gating, particularly in rolling to finished dimensions or from center to center. In such cases, the gating indicates the exact points at which to separate the blanks. Such a gating is also very effective in rollingblanks more particularly of the forms shown in Figures 2, 3,7, as it gives the rollsa bite on the leader and prevents slipping thereof when rolling the rectangular end portions. This insures accurate rolling, and minimizes the number of blanks which must be scrapped.

In all the forms it will be understood that the dierolls turn out a connected integral string or series of these blanks which are then separated from eachother, the blanks either being directly connected end to end or having a gating or portion to shear away between their ends. It will be noted that in each form there is a portion or portions of the axle rolled to finished dimensions and that in some of the cases forging of arts is necessary as well as machining, w ile in other cases, such as that of Figure 6 the axle requires only machining after the flash or fins are trimmed away.

During the rolling step the articles are extruded in a greater or less amount, depending upon the amount of reduction. In this respect my invention difi'ers materiall from processes wherein bearing balls or the like are pressed out of a strip. Such operations are essentially continuous pressing schemes and are not true rolling or extrusion processes. 1

The advantages of my invention will be obvious to those skilled in the art, since an inexpensive semi-finished product is afiorded which is rolled substantially to proper length between centers, thereby eatly re ducing the amount'of after woi li thereon. The present invention also cuts the hammer size required for the forging operations, insures a more uniform product, and increases production.

Many changes may he made in the form and size of the axle depending on the type desired and other changes may' be made without departing from my invention. The broad method may also be a lied to making blanks other than axle hlhnks, as disclosed in my Patent 1,572,343, dated Fehruary 9th, 1926. The axle blanks herein described are claimed in my divisional application Serial No. 201,316, filed June 25, 1927.

I claim:

1. In the manufacture of die-rolled articles, the'steps consisting of rolling a leader of rudimentary I-beam cross-section, and then die-rolling the leader and imparting varying cross-sectional shape thereto.

2. In the manufacture of axle blanks, the steps consisting of tormin a rudimentary blank of uniform cross-section and of rudimentary I-beam shape, and then die-rolling the same to form anaxle blank of varying cross-sectional I-beam shape and having spring seats.

3. In the manufacture of axle blanks, the steps consisting of forming a rudimentary blank of uniform cross-section and of rudimentary ill-beam shape, and then die-rolling the same to form an axle blank of varying cross-sectional I-beam shape and having spring seats, and simultaneously re-forming tllle end portions of the blank into solid s ape.

4. In the method of die rolling a non-circular shape which is substantially symmetrical about the common plane ofthe rolls, the steps consisting in supplying to the rolls a similarly substantially symmetrical leader having a rudimentary shape corresponding generally to a section of the article to be rolled, and forming a flash lying substantially in such plane. I

5. In the method of making die rolled blanks of varying cross-sectional shape and having a recessed portion, the steps consisting of forming a blank whose cross-sectional shape is a rudimentary recessed shape corresponding roughly to that of the recessed portion of the final'blank desired, and then die rolling said blank.

6. In the method of making axle blanks of varying cross-sectional shape and having a recessed portion, the steps consisting of forming a rudimentar blank of uniform recessed cross section t roughout and corresponding roughly to the cross-sectional shape of the recessed ortion of the final blank, and then die rolling the rudimentary blank to form an axle blank.

In testimony whereof I have hereunto set my hand.

WILLIAM P. WITHEROW. 

